U.S. patent number 8,973,268 [Application Number 13/696,632] was granted by the patent office on 2015-03-10 for methods of making multi-chromatic dental appliances.
This patent grant is currently assigned to 3M Innovative Properties Company. The grantee listed for this patent is Ryan E. Johnson, Naimul Karim. Invention is credited to Ryan E. Johnson, Naimul Karim.
United States Patent |
8,973,268 |
Johnson , et al. |
March 10, 2015 |
**Please see images for:
( Certificate of Correction ) ** |
Methods of making multi-chromatic dental appliances
Abstract
A method of making a multi-chromatic dental appliance. A first
article can be formed of a first material based on a first digital
surface representation having a desired outer shape of the dental
appliance. A portion of the first article can then be removed to
form an outer layer of the dental appliance comprising a cavity
dimensioned to accommodate an inner layer. A second article can be
formed by filling the cavity of the first article with a second
material. The second material can have at least one different
optical property than the first material. The second article can be
further processed, as desired. For example, a desired inner shape
of the dental appliance can be formed in the second article. Such a
desired inner shape can be based on a second digital surface
representation of a dental object configured to receive the dental
appliance.
Inventors: |
Johnson; Ryan E. (St. Paul,
MN), Karim; Naimul (Maplewood, MN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson; Ryan E.
Karim; Naimul |
St. Paul
Maplewood |
MN
MN |
US
US |
|
|
Assignee: |
3M Innovative Properties
Company (St. Paul, MN)
|
Family
ID: |
44370699 |
Appl.
No.: |
13/696,632 |
Filed: |
June 6, 2011 |
PCT
Filed: |
June 06, 2011 |
PCT No.: |
PCT/US2011/039228 |
371(c)(1),(2),(4) Date: |
November 07, 2012 |
PCT
Pub. No.: |
WO2011/159503 |
PCT
Pub. Date: |
December 22, 2011 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20130081272 A1 |
Apr 4, 2013 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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61355876 |
Jun 17, 2010 |
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Current U.S.
Class: |
29/896.1;
700/118; 700/119; 29/896.11; 264/19; 264/16 |
Current CPC
Class: |
A61C
13/082 (20130101); A61C 13/0006 (20130101); A61C
13/0003 (20130101); A61C 5/77 (20170201); A61C
13/0004 (20130101); A61C 3/00 (20130101); A61C
13/09 (20130101); Y10T 29/49568 (20150115); Y10T
29/49567 (20150115); A61C 8/005 (20130101); A61C
8/008 (20130101) |
Current International
Class: |
A61C
5/10 (20060101); A61C 13/20 (20060101) |
Field of
Search: |
;29/896.1,896.11
;264/16,19 ;700/118,119 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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WO 2009/070469 |
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Jun 2009 |
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WO |
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WO 2010/074890 |
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Jul 2010 |
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WO |
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WO 2010/093534 |
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Aug 2010 |
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WO |
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WO 2011/159520 |
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Dec 2011 |
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WO |
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Other References
International Search Report PCT/US2011/039228 May 9, 2011, 3 pgs.
cited by applicant.
|
Primary Examiner: Taousakis; Alexander P
Attorney, Agent or Firm: Einerson; Nicole J.
Claims
What is claimed is:
1. A method of making a dental appliance, the method comprising:
providing a first digital surface representation of a desired outer
shape of a dental appliance; forming a first article of a first
material having the desired outer shape based on the first digital
surface representation; removing an inner portion of the first
article to form an outer layer of the dental appliance comprising a
cavity dimensioned to accommodate an inner layer; and forming a
second article by filling the cavity of the first article with a
second material adapted to form the inner layer, wherein the second
material has at least one optical property that is different from
the first material.
2. A method of making a dental appliance, the method comprising:
providing a first digital surface representation of a desired outer
shape of a dental appliance; forming a first article of a first
material having the desired outer shape based on the first digital
surface representation; removing an inner portion of the first
article to form an outer layer of the dental appliance comprising a
cavity dimensioned to accommodate an inner layer; forming a second
article by filling the cavity of the first article with a second
material adapted to form the inner layer, wherein the second
material has at least one optical property that is different from
the first material; providing a dental object having an outer shape
comprising the negative of a desired inner shape of the dental
appliance; acquiring a second digital surface representation of the
outer shape of the dental object; and subtractively forming the
desired inner shape in the second article based on the second
digital surface representation to form the dental appliance having
the desired inner shape and the desired outer shape; wherein at
least one of providing a dental object and acquiring a second
digital surface representation occurs during or after at least one
of forming a first article, removing an inner portion of the first
article, and forming a second article, and wherein subtractively
forming the desired inner shape occurs separately from and
subsequently to forming a first article of a first material having
the desired outer shape.
3. The method of claim 1, further comprising repeating the removing
an inner portion of the first article step and the forming a second
article step as many times as desired to form a second article
having a desired number of layers and comprising the inner
layer.
4. The method of claim 1, wherein the second material is different
from the first material.
5. The method of claim 1, wherein the first material has a
different shade than the second material.
6. The method of claim 1, wherein the first material is shaded to
mimic an enamel layer, and wherein the second material is shaded to
mimic a dentin layer.
7. The method of claim 1, wherein the first material is formed of
at least one of at least one of a polymeric composite and a
glass-ceramic.
8. The method of claim 1, wherein the second material is formed of
at least one of at least one of a polymeric composite and a
glass-ceramic, and wherein the second material includes at least
one optical property that differs from the first material.
9. The method of claim 1, wherein the first material is formed of a
glass-ceramic or a polymeric composite material, and wherein the
second material is formed of a polymeric composite material.
10. The method of claim 1, wherein the dental object includes at
least one of a tooth stump, an implant, an implant abutment, a
healing cap, and a combination thereof.
11. The method of claim 1, wherein forming a first article of a
first material having the desired outer shape includes forming a
first article by a subtractive process.
12. The method of claim 1, wherein forming a first article of a
first material having the desired outer shape includes machining
the desired outer shape from a mill block.
13. The method of claim 12, wherein the mill block is formed of a
polymeric composite material.
14. A method of making a dental appliance, the method comprising:
providing a first digital surface representation of a desired outer
shape of a dental appliance; forming a first article of a first
polymeric material having the desired outer shape based on the
first digital surface representation; removing an inner portion of
the first article to form an outer layer of the dental appliance
comprising a cavity dimensioned to accommodate an inner layer;
forming a second article by filling the cavity of the first article
with a second polymeric material, wherein the second polymeric
material has at least one optical property that is different from
the first polymeric material; curing the second polymeric material
to form the inner layer; providing a dental object having an outer
shape comprising the negative of a desired inner shape of the
dental appliance; acquiring a second digital surface representation
of the outer shape of the dental object; and subtractively forming
the desired inner shape in the second article based on the second
digital surface representation to form the dental appliance having
the desired inner shape and the desired outer shape; wherein at
least one of providing a dental object and acquiring a second
digital surface representation occurs during or after at least one
of forming a first article, removing an inner portion of the first
article, and forming a second article, and wherein subtractively
forming the desired inner shape occurs separately from and
subsequently to forming a first article having the desired outer
shape.
15. The method of claim 14, further comprising repeating the
removing an inner portion of the first article step and the forming
a second article step as many times as desired to form a second
article having a desired number of layers and comprising the inner
layer.
Description
FIELD
The present disclosure is generally related to methods and
workflows of making layered dental appliances, such as temporary or
permanent dental restorations; particularly, to digital workflows
for making multi-chromatic dental appliances; and more
particularly, to at least partially chairside digital workflows for
making layered, multi-chromatic dental appliances.
BACKGROUND
Digital dentistry generally includes using or creating one or more
digital data files to prepare a dental appliance having a desired
outer and/or inner shape and dimension. In some existing workflows,
a desired outer shape of a final dental appliance can be
determined; a tooth can be prepared (e.g., ground to a tooth
stump); and a desired inner shape of the final dental appliance can
be determined from the prepared tooth. A data file comprising the
desired outer shape and the desired inner shape can then be used to
create the final dental appliance having a desired outer and inner
shape. For example, in some existing systems, the dental appliance
can be formed by milling. However, milled dental appliances
generally have a monolithic visual appearance, and uniform
structural properties throughout, due to the corresponding,
monolithic composition of dental mill blanks.
SUMMARY
The present disclosure generally relates to workflows that allow a
desired outer shape (i.e., external surface, contours, etc.) of a
dental appliance to be determined and created separately from that
of a desired inner shape (i.e., internal surface, contours, etc.,
e.g., for accommodating a prepared tooth, an implant, an implant
abutment, healing cap, or the like, or combinations thereof) of the
same dental appliance; thus, generally separating the step for
preparing the desired outer shape from the step for preparing the
desired inner shape of a dental appliance.
Furthermore, the present disclosure generally relates to workflows
that allow a desired outer layer of a dental appliance to be
determined and created separately from that of a desired inner
layer of the same dental appliance. The outer layer of the dental
appliance can include a desired outer shape, as well as a desired
inner shape or cavity. The inner layer of the dental appliance can
also include a desired outer shape (e.g., that can match the inner
shape of the outer layer, or that can be sized to accommodate
cement or adhesive between the layers), and a desired inner shape
(e.g., for accommodating a prepared tooth, an implant, an implant
abutment, healing cap, or the like, or combinations thereof). For
example, the inner layer can include a dental core or framework of
a dental restoration. As a result, methods of the present
disclosure can include separation of (e.g., temporally and/or
spatially) the steps for designing and creating an outer layer of a
dental appliance from steps for designing and creating an inner
layer of the same dental appliance.
Some embodiments of the present disclosure provide a method of
making a dental appliance. The method can include providing a first
digital surface representation of a desired outer shape of a dental
appliance, and forming a first article having the desired outer
shape based on the first digital surface representation. The method
can further include providing a dental object having an outer shape
comprising the negative of a desired inner shape of the dental
appliance; acquiring a second digital surface representation of the
outer shape of the dental object; and subtractively forming the
desired inner shape in the first article based on the second
digital surface representation to form the dental appliance having
the desired inner shape and the desired outer shape. At least one
of providing a dental object and acquiring a second digital surface
representation can occur during or after forming a first article.
Furthermore, subtractively forming the desired inner shape can
occur separately from and subsequently to forming a first article
having the desired outer shape.
Some embodiments of the present disclosure provide a method of
making a dental appliance. The method can include providing a first
digital surface representation of a desired outer shape of a dental
appliance, and forming a first article of a first material having
the desired outer shape based on the first digital surface
representation. The method can further include removing an inner
portion of the first article to form an outer layer of the dental
appliance comprising a cavity dimensioned to accommodate an inner
layer, and forming a second article by filling the cavity of the
first article with a second material adapted to form the inner
layer. The second material can have at least one different optical
property than the first material.
Some embodiments of the present disclosure provide a method of
making a dental appliance. The method can include providing a first
digital surface representation of a desired outer shape of a dental
appliance, and forming a first article of a first material having
the desired outer shape based on the first digital surface
representation. The method can further include removing an inner
portion of the first article to form an outer layer of the dental
appliance comprising a cavity dimensioned to accommodate an inner
layer, and forming a second article by filling the cavity of the
first article with a second material adapted to form the inner
layer. The second material can have at least one different optical
property than the first material. The method can further include
providing a dental object having an outer shape comprising the
negative of a desired inner shape of the dental appliance, and
acquiring a second digital surface representation of the outer
shape of the dental object. The method can further include
subtractively forming the desired inner shape in the second article
based on the second digital surface representation to form the
dental appliance having the desired inner shape and the desired
outer shape. In some embodiments, at least one of providing a
dental object and acquiring a second digital surface representation
can occur during or after at least one of forming a first article,
removing an inner portion of the first article, and forming a
second article. In addition, in some embodiments, subtractively
forming the desired inner shape can occur separately from and
subsequently to forming a first article of a first material having
the desired outer shape.
Some embodiments of the present disclosure provide a method of
making a dental appliance. The method can include providing a first
digital surface representation of a desired outer shape of a dental
appliance, and forming a first article of a first polymeric
material having the desired outer shape based on the first digital
surface representation. The method can further include removing an
inner portion of the first article to form an outer layer of the
dental appliance comprising a cavity dimensioned to accommodate an
inner layer, and forming a second article by filling the cavity of
the first article with a second polymeric material. The second
polymeric material can have at least one different optical property
than the first polymeric material. The method can further include
curing the second polymeric material to form the inner layer. The
method can further include providing a dental object having an
outer shape comprising the negative of a desired inner shape of the
dental appliance, and acquiring a second digital surface
representation of the outer shape of the dental object. The method
can further include subtractively forming the desired inner shape
in the second article based on the second digital surface
representation to form the dental appliance having the desired
inner shape and the desired outer shape. At least one of providing
a dental object and acquiring a second digital surface
representation can occur during or after at least one of forming a
first article, removing an inner portion of the first article, and
forming a second article. Subtractively forming the desired inner
shape can occur separately from and subsequently to forming a first
article of a first material having the desired outer shape.
Other features and aspects of the present disclosure will become
apparent by consideration of the detailed description and
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a flowchart of a method of making a layered,
multi-chromatic dental appliance, according to one embodiment of
the present disclosure.
DETAILED DESCRIPTION
Before any embodiments of the present disclosure are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise,
the terms "affixed," and "coupled" and variations thereof are used
broadly and encompass both direct and indirect affixations and
couplings. Further, "coupled" is not restricted to physical or
mechanical connections or couplings. It is to be understood that
other embodiments may be utilized, and structural or logical
changes may be made without departing from the scope of the present
disclosure. Furthermore, terms such as "front," "rear," "top,"
"bottom," "upper," "lower," and the like are only used to describe
elements as they relate to one another, but are in no way meant to
recite specific orientations of the apparatus, to indicate or imply
necessary or required orientations of the apparatus, or to specify
how the invention described herein will be used, mounted,
displayed, or positioned in use.
Some embodiments of the present disclosure generally relate to
methods and workflows for making dental appliances, such as
temporary or permanent dental restorations. Particularly, some
embodiments generally relate to digital workflows for making dental
appliances that do not require the final outer shape and the final
inner shape of a dental appliance both be known prior to performing
a first (e.g., outer) machining step. By not requiring that both
the inner and outer shapes be known prior to any machining steps,
machining a desired outer shape of the dental appliance can be
performed separately from machining a desired inner shape. Further
information and details regarding such methods can be found in
co-pending U.S. Application No. 61/355,872, entitled, "METHODS OF
MAKING DENTAL APPLIANCES," filed Jun. 17, 2010, which is
incorporated herein by reference in its entirety.
The desired outer shape can be provided by an outer layer of the
dental appliance, while the desired inner shape (which can be
designed to accommodate a prepared tooth stump, an implant, an
implant abutment, healing cap, or the like, or combinations
thereof) can be provided by an inner layer of the dental appliance.
Such dental objects, for example, can lack tooth-shaped
supragingival exterior surfaces.
In some embodiments, as described in PCT Publication WO
2010/093534, the dental object (e.g., a healing cap) can be formed
of a sufficiently malleable material such that the dental object
can be customized in shape prior to hardening. In such embodiments,
the inner shape of the dental appliance formed by processes of the
present disclosure may not be so specifically controlled or
designed, but rather can be designed to fit over a dental object
that can conform to fit within the inner shape of the dental
appliance. For example, the dental appliance can be pressed onto a
malleable dental object, which can then be hardened.
The present disclosure also generally relates to methods and
workflows for making dental appliances that do not require the
outer layer and the inner layer of a dental appliance both be
designed and known prior to creating the outer layer. By not
requiring that both the outer layer and the inner layer be known
prior to any forming (e.g., machining) steps, forming a desired
outer layer of the dental appliance can be performed separately
from forming a desired inner layer.
The outer layer and the inner layer, and any other layers,
described herein that are formed by methods of the present
disclosure generally include major or significant portions of the
resulting dental appliance, and generally do not include bonding
materials or bonding layers, such as cement or adhesives used, for
example, to couple the dental appliance to a dental object (e.g., a
tooth stump) and/or to couple layers of the dental appliance
together. For example, in some embodiments, the outer layer, the
inner layer, and any other layers described herein as forming a
portion the dental appliance, generally form at least about 80% by
volume (vol %) of the dental appliance, in some embodiments, at
least about 90% by volume, and in some embodiments, at least about
95% by volume. Bonding materials, such as cement used to couple
together layers of the dental appliance and/or to couple the dental
appliance to a dental object, if employed, generally do not
significantly contribute to the overall optical properties of the
dental appliance.
Furthermore, some embodiments of the present disclosure generally
relate to methods and workflows for making layered, multi-chromatic
dental appliances, such that the outer layer and the inner layer
will be different with respect to at least one optical property. As
used herein, the term "multi-chromatic" generally refers to an
object (e.g., a dental appliance) that includes two or more layers,
and wherein each layer is different from another layer with respect
to at least one optical property. Such optical properties can
include, but are not limited to, color or shade,
transparency/translucency/opacity, reflectance, gloss or shine,
refractive index, other suitable optical properties, or
combinations thereof. Such optical properties can typically be
visually distinguishable by the naked human eye.
By providing an inner layer and an outer layer of different optical
properties, a more natural-looking and aesthetically-pleasing
dental appliance can be formed. For example, in the case of dental
restorations, such as crowns and bridges, an outer layer can
include a certain level of translucency and can be shaded to mimic
an enamel layer, while the inner layer can include a certain level
of opacity and can be shaded to mimic a dentin layer (e.g., the
inner layer can be slightly darker in color than the outer layer).
In the case of bridges, each tooth unit on the bridge can include
an interior cavity that is milled (i.e., to form an outer layer)
and filled to form an inner layer of a different optical property
(e.g., shade) than the outer layer. In some embodiments, the inner
layer can be provided by a composite material, such that internal
shading of the dental appliance can be performed using a process
similar to that for filling cavities in natural teeth.
While the present disclosure may emphasize certain steps and
certain types of dental articles, it will be understood that
additional variations, adaptations, and combinations of the methods
and systems below will be apparent to one of ordinary skill in the
art. For example, there are a number of variants to
computer-controlled milling that may be suitably employed.
Similarly, various types of cured or partially-cured materials may
be employed for various fabrication steps, and a number of
three-dimensional scanning technologies are available that might be
suitably adapted to obtaining three-dimensional scans for the uses
described herein. All such variations, adaptations, and
combinations are intended to fall within the scope of this
disclosure.
Methods and workflows for making biomimetic dental appliances are
described in co-pending U.S. Application No. 61/355,883, entitled
"METHODS OF MAKING BIOMIMETIC DENTAL APPLIANCES," filed Jun. 17,
2010, which is incorporated herein by reference in its
entirety.
The methods of the present disclosure will generally be described
as forming a two-layer dental appliance, including an outer layer
and an inner layer. However, it should be understood that as many
layers as necessary can be formed according to the techniques
described herein, and the description of two layers is used only
for simplicity and clarity. The phrases "outer layer" and "inner
layer" can be used to describe an "outermost layer" and an
"innermost layer," and as many intermediate layers as necessary can
be formed between the outermost layer and the innermost layer,
following the methods and workflows described herein.
The phrase "dental article" is to be understood as an article which
can and is to be used in the dental or orthodontic area including
dental laboratories, and can be used to described even
intermediates in a dental workflow process.
The phrase "dental appliance" generally refers to any dental or
orthodontic appliance or restoration, dental mill blank, prosthetic
device, or combination thereof. The appliance may be a finished
appliance ready for introduction into the mouth of a patient, an
appliance without the finishing (e.g. without stains) but with its
final shape (i.e., a "net shape" appliance), or it may be a
preformed or near-final dental appliance (i.e., a "near-net shape"
appliance) subject to further processing before use, such as a
dental mill blank.
The phrases "mill block," "block," "blank," "mill blank," and
"dental mill blank" generally refer to a solid block of material
from which a desired product (e.g., a dental restoration) can be
machined, and is not limited to the type of machining that will be
used, even if referred to as a "mill" block. A mill block may have
a size of about 10 mm to about 30 mm in two dimensions, for example
may have a diameter in that range, and may be of a certain length
in a third dimension. A mill block for making a single crown may
have a length of about 15 mm to about 30 mm, and a blank for making
bridges may have a length of about 40 mm to about 80 mm. In some
embodiments, a mill block used for making a single crown can have a
diameter of about 24 mm and a length of about 19 mm. In some
embodiments, a mill block used for making bridges can have a
diameter of about 24 mm and a length of about 58 mm. In general,
mill blanks are attached to a mandrel that fits into a milling
machine. The term mandrel can also be understood to include other
methods of mounting mill blanks, such as frames (e.g., a Lava frame
available from 3M ESPE, Seefeld, Germany).
The term "machining" generally refers to shaping a material by a
machine, and can be employed to create custom-fit dental appliances
having a desired shape and morphology. Machining can include, but
is not limited to, one or more of milling, grinding, cutting,
carving, abrading, polishing, controlled vaporization, electronic
discharge milling (EDM), cutting by water jet or laser, any other
suitable method of cutting, removing, shaping or carving material,
or a combination thereof. In some cases, milling can be faster and
more cost-effective than grinding. The term "mill block" or "blank"
can be used to describe a starting material that will be machined
to form a dental appliance.
While machining a mill block using a hand-held tool or instrument
is possible, preferably the prosthetic is milled by machine,
including computer controlled milling equipment. Some embodiments
of the present disclosure employs a CAD/CAM device capable of
milling a block, such as the Cerec System (available from Sirona
Dental Systems, Germany). By using a CAD/CAM machining (e.g.,
milling) device, the dental appliance can be fabricated efficiently
and with precision. During machining, the contact area may be dry,
or it may be flushed with a lubricant. Alternatively, it may be
flushed with an air or gas stream. Suitable lubricants can include
water, oil, glycerin, ethylene glycols, silicones, or combinations
thereof. After machining, some degree of finishing, polishing and
adjustment may be necessary to obtain a custom fit and/or aesthetic
appearance.
The phrase "dental restoration" is generally used to refer to any
restoration that can be used in the dental field, including, but
not limited to, crowns, partial crowns, inlays, onlays, abutments,
bridges (e.g., including 2-unit, 3-unit, 4-unit, 5-unit or 6-unit
bridges), implants, healing caps, other suitable dental articles,
and combinations thereof. The dental restoration can include a
three-dimensional inner and outer surface including convex and
concave structures. The thickness of a dental restoration can vary
from very thin, for example at its edges and rims (e.g., less than
about 0.1 mm) to considerably thick, for example, in the biting, or
occlusal, area (e.g., up to about 7 mm). In some embodiments, the
thickness of a dental restoration ranges from 0.3 mm to 0.5 mm. In
some embodiments, the dental restoration can comprise or consist
essentially of a glass ceramic, a polymeric composite, or a
combination thereof.
Methods of the present disclosure can generally include the
following steps: (i) providing a first digital surface
representation corresponding to a desired outer shape of a dental
appliance; (ii) forming a first article of a first material having
the desired outer shape that corresponds to the first digital
surface representation; (iii) removing an inner portion of the
first article to form an outer layer of the dental appliance
comprising a cavity dimensioned to accommodate an inner layer; (iv)
forming a second article by filling the cavity of the first article
with a second material adapted to form the inner layer, the second
article still including the desired outer layer and outer shape;
(v) providing a dental object having an outer shape comprising the
negative of a desired inner shape of the dental appliance; (vi)
acquiring a second digital surface representation of the outer
shape of the dental object; and (vii) subtractively forming (e.g.,
machining) the desired inner shape in the second article (e.g., in
the inner layer of the second article) that corresponds to the
second digital surface representation to form the dental appliance
having the desired inner shape and the desired outer shape; wherein
at least one of steps (v) and (vi) can occur during or after any or
all of steps (ii)-(iv), such that any or all of steps (ii)-(iv) (or
even steps (i)-(iv)) can occur at least partially simultaneously
with steps (v) and (vi); and wherein step (vii) occurs separately
from and subsequently to steps (ii)-(iv).
In some embodiments, following the above steps (i)-(vii), the
method can further include step (viii) in which the dental
appliance is placed in the patient's mouth.
In some embodiments, all of the above steps (i)-(viii) can be
performed "chairside," such that all of the steps occur during one
patient appointment or visit, e.g., at a dentist's office. In some
embodiments, at least some of the above steps (e.g., any or all of
steps (i)-(iv)) can be performed prior to (and potentially at a
different location from) the appointment in which the remaining
steps occur. The phrase "dentist's office" is used herein to
generally refer to a facility or venue (e.g., a healthcare
facility, a clinic, a dentist's office, an orthodontist's office,
or the like) in which a patient would be prepared to receive, and
would receive, a dental appliance. As such, the phrase "dentist's
office" is not intended to be overly limiting, and is used only for
simplicity.
The methods of the present disclosure can be "mold-free" methods,
in which the outer shape and inner shape can be formed directly
from the first digital surface representation and the second
digital surface representation, respectively, without first
creating an intermediate or temporary structure, such as a
mold.
Step (i): Providing a First Digital Surface Representation
In some embodiments, step (i) above, "providing a first digital
surface representation corresponding to a desired outer shape," can
include performing a digital data capture of a patient's anatomy
via digital impressioning (e.g., optically scanning a patient's
mouth, which is described in greater detail below), or computed
tomography (CT) (or computer-aided tomography (CAT)).
Alternatively, the data capture can indirectly capture the
patient's anatomy by performing a digital data capture of a plaster
model (e.g., of the patient's mouth) or of a dental impression
(e.g., of the patient's mouth), rather than directly capturing the
patient's anatomy. In the case of using a dental impression, the
digital data capture can be inverted from a negative volume to a
positive volume. As a result, the first digital surface
representation can be obtained prior to the time or date at which
the remaining steps occur. Alternatively, or additionally, at least
a portion of the first digital surface representation can be
provided by a series of tooth libraries, or databases, that can be
adaptive to replicate a portion or all of a tooth, which may be
necessary for a severely worn, fractured, or implant usage,
altogether absent tooth.
Performing a digital data capture can also be referred to as
performing a digital workflow. Such a digital workflow can include
optically scanning an object (e.g., a patient's mouth, a plaster
model, an impression, etc.) to develop one or more digital data
files (e.g., which can form, or be consolidated to form, a digital
surface representation) representative of the desired dental
appliance. Particularly, in step (i), the digital workflow is used
to develop various images for the desired outer shape of the
desired dental appliance. Such scanning can be performed using an
optical scanner that is coupled to a computer-aided design (CAD)
system that functions in conjunction with a computer-integrated
manufacturing (CIM) system. Such a CIM system is available, for
example, under the trade designation LAVA.TM. from 3M ESPE AG
(Seefeld, Germany). Such optical scanning processes will now be
described in greater detail.
In some embodiments, the first digital surface representation can
be provided by a tooth library; can be known (e.g., stored in a
library or in a patient's file history) from a previous digital
data capture; the digital data capture can be taken at the same
visit in which the patient will receive the finished dental
appliance; or a combination thereof.
An example of a three-dimensional scanning system that may be
employed in executing methods of the present disclosure is
described in PCT Publication No. WO2009/070469 (Docket No.
63525WO003), entitled "Fabrication of Dental Articles using
Digitally-controlled Reductive and Digitally-controlled Additive
Processes," filed on Nov. 18, 2008, which is incorporated herein by
reference in its entirety.
In the following description, the term "image" generally refers to
a two-dimensional set of pixels forming a two-dimensional view of a
subject within an image plane. The term "image set" generally
refers to a set of related two dimensional images that might be
resolved into three-dimensional data. The term "point cloud"
generally refers to a three-dimensional set of points forming a
three-dimensional view of the subject reconstructed from a number
of two-dimensional views. In a three-dimensional image capture
system, a number of such point clouds may also be registered and
combined into an aggregate point cloud constructed from images
captured by a moving camera. Thus it will be understood that pixels
generally refer to two-dimensional data and points generally refer
to three-dimensional data, unless another meaning is specifically
indicated or clear from the context.
The terms "three-dimensional surface representation," "digital
surface representation," "three-dimensional surface map,"
"three-dimensional model," and the like, as used herein, are
intended to refer to any three-dimensional surface map of an
object, such as a point cloud of surface data, a set of
two-dimensional polygons, or any other data representing all or
some of the surface of an object, as might be obtained through the
capture and/or processing of three-dimensional scan data, unless a
different meaning is explicitly provided or otherwise clear from
the context. A "three-dimensional representation" may include any
of the three-dimensional surface representations described above,
as well as volumetric and other representations, unless a different
meaning is explicitly provided or otherwise clear from the
context.
Acquiring digital surface representation of intraoral structures is
generally known. For example, U.S. Pat. No. 7,698,014; incorporated
herein by reference, describes a method of acquiring a digital
surface representation of one or more intraoral surfaces and
processing the digital surface representation to obtain a
three-dimensional model. Such a method can be employed in the
methods of the present disclosure to obtain a first digital surface
representation.
As described in U.S. Pat. No. 7,698,014, FIG. 2 shows an image
capture system 200 that may include a scanner 202 that captures
images from a surface 206 of a subject 204, such as a dental
patient, and forwards the images to a computer 208, which may
include a display 210 and one or more user input devices such as a
mouse 212 or a keyboard 214. The scanner 202 may also include an
input or output device 216 such as a control input (e.g., button,
touchpad, thumbwheel, etc.) or a display (e.g., LCD or LED display)
to provide status information.
The scanner 202 may include any camera or camera system suitable
for capturing images from which a three-dimensional point cloud may
be recovered. For example, the scanner 202 may employ a
multi-aperture system as disclosed, for example, in US Patent
Publication No. 2004/0155975 to Hart et al ("Hart"). While Hart
discloses one multi-aperture system, it will be appreciated that
any multi-aperture system suitable for reconstructing a
three-dimensional point cloud from a number of two-dimensional
images may similarly be employed in the methods of the present
disclosure. In one multi-aperture embodiment, the scanner 202 may
include a plurality of apertures including a center aperture
positioned along a center optical axis of a lens and any associated
imaging hardware. The scanner 202 may also, or instead, include a
stereoscopic, triscopic or other multi-camera or other
configuration in which a number of cameras or optical paths are
maintained in fixed relation to one another to obtain
two-dimensional images of an object from a number of slightly
different perspectives. The scanner 202 may include suitable
processing for deriving a three-dimensional point cloud from an
image set or a number of image sets, or each two-dimensional image
set may be transmitted to an external processor such as contained
in the computer 208 described below. In other embodiments, the
scanner 202 may employ structured light, laser scanning, direct
ranging, or any other technology suitable for acquiring
three-dimensional data, or two-dimensional data that can be
resolved into three-dimensional data.
In one embodiment, the scanner 202 is a handheld, freely
positionable probe having at least one user input device 216, such
as a button, lever, dial, thumb wheel, switch, or the like, for
user control of the image capture system 200 such as starting and
stopping scans. In an embodiment, the scanner 202 may be shaped and
sized for dental scanning. More particularly, the scanner may be
shaped and sized for intraoral scanning and data capture, such as
by insertion into a mouth of an imaging subject and passing over an
intraoral surface 206 at a suitable distance to acquire surface
data from teeth, gums, and so forth. The scanner 202 may, through
such a continuous acquisition process, capture a point cloud of
surface data having sufficient spatial resolution and accuracy to
prepare a dental model, either directly or through a variety of
intermediate processing steps.
Although not shown in FIG. 2, it will be appreciated that a number
of supplemental lighting systems may be employed during image
capture. For example, environmental illumination may be enhanced
with one or more spotlights illuminating the subject 204 to speed
image acquisition and improve depth of field (or spatial resolution
depth). The scanner 202 may also, or instead, include a strobe,
flash, or other light source to supplement illumination of the
subject 204 during image acquisition.
The computer 208 may be, for example, a personal computer or other
processing device. In one embodiment, the computer 208 includes a
personal computer with a dual 2.8 GHz Opteron central processing
unit, 2 gigabytes of random access memory, a TYAN Thunder K8WE
motherboard, and a 250 gigabyte, 10,000 rpm hard drive. This system
may be operated to capture approximately 1,500 points per image set
in real time using the techniques described herein, and store an
aggregated point cloud of over one million points. As used herein,
the term "real time" means generally with no observable latency
between processing and display. In a video-based scanning system,
real time more specifically refers to processing within the time
between frames of video data, which may vary according to specific
video technologies between about fifteen frames per second and
about thirty frames per second. More generally, processing
capabilities of the computer 208 may vary according to the size of
the subject 204, the speed of image acquisition, and the desired
spatial resolution of three-dimensional points. The computer 208
may also include peripheral devices such as a keyboard 214, display
210, and mouse 212 for user interaction with the camera system 200.
The display 210 may be a touch screen display capable of receiving
user input through direct, physical interaction with the display
210.
Communications between the computer 208 and the scanner 202 may use
any suitable communications link including, for example, a wired
connection or a wireless connection based upon, for example, IEEE
802.11 (also known as wireless Ethernet), BlueTooth, or any other
suitable wireless standard using, e.g., a radio frequency,
infrared, or other wireless communication medium. In medical
imaging or other sensitive applications, wireless image
transmission from the scanner 202 to the computer 208 may be
secured. The computer 208 may generate control signals to the
scanner 202 which, in addition to image acquisition commands, may
include conventional camera controls such as focus or zoom.
In an example of general operation of a three-dimensional image
capture system 200, the scanner 202 may acquire two-dimensional
image sets at a video rate while the scanner 202 is passed over a
surface of the subject. The two-dimensional image sets may be
forwarded to the computer 208 for derivation of three-dimensional
point clouds. The three-dimensional data for each newly acquired
two-dimensional image set may be derived and fitted or "stitched"
to existing three-dimensional data using a number of different
techniques. Such a system employs camera motion estimation to avoid
the need for independent tracking of the position of the scanner
202. One useful example of such a technique is described in
commonly-owned U.S. Pat. No. 7,605,817, incorporated herein by
reference. However, it will be appreciated that this example is not
limiting, and that the principles described herein may be applied
to a wide range of three-dimensional image capture systems.
The display 210 may include any display suitable for video or other
rate rendering at a level of detail corresponding to the acquired
data. Suitable displays include cathode ray tube displays, liquid
crystal displays, light emitting diode displays and the like. In
some embodiments, the display may include a touch screen interface
using, for example capacitive, resistive, or surface acoustic wave
(also referred to as dispersive signal) touch screen technologies,
or any other suitable technology for sensing physical interaction
with the display 210.
The digital surface representation may be processed with one or
more post-processing steps. This may include a variety of data
enhancement processes, quality control processes, visual
inspection, and so forth. Post-processing steps may be performed at
a remote post-processing center or other computer facility capable
of post-processing the imaging file, which may be, for example a
dental laboratory. In some cases, this post-processing may be
performed by the image capture system 200. Post-processing may
involve any number of clean-up steps, including the filling of
holes, removing of outliers, etc.
Data enhancement may include, for example, smoothing, truncation,
extrapolation, interpolation, and any other suitable processes for
improving the quality of the digital surface representation or
improving its suitability for an intended purpose. In addition,
spatial resolution may be enhanced using various post-processing
techniques. Other enhancements may include modifications to the
data, such as forming the digital surface representation into a
closed surface by virtually providing a base for each arch, or
otherwise preparing the digital surface representation for
subsequent fabrication steps.
As a result, such an above-described digital workflow includes
scanning to capture a three-dimensional representation of some or
all of the dentition of a patient's intraoral surfaces, at least at
the desired location, i.e. typically the tooth structures directly
adjacent those that will come in contact with the dental appliance
that will be placed in the patient's mouth. This can sometimes be
referred to as capturing the "pre-op" condition, and can include
capturing a representation of soft tissue as well as dentition.
As mentioned above, in some embodiments, at least a portion of a
tooth may be missing or broken. In such cases, a library of tooth
forms for each human tooth (e.g., the first molar) may be provided
by software and used to form the first digital surface
representation, or merged with any acquired digital data files to
form the first digital surface representation.
Thus, the digital surface representations may be created by
consolidating or merging various digital data files (e.g.,
including data files acquired by optically scanning and/or data
files previously acquired and/or provided by tooth libraries), and
the digital data files or the resulting digital surface
representation can be transmitted to a rapid fabrication facility
such as a dental laboratory, an in-house dental laboratory at a
dentist's office, or any other facility with machinery to fabricate
physical models from digital models. In yet another embodiment, the
digital surface representations may be downloaded from an internet
site.
Any suitable optical scanner that can perform the above-described
optical scanning procedures can be employed in step (i) of the
method. Two exemplary optical scanners include a Cerec System,
available from Sirona Dental Systems (Germany), and an E4D Dentist
Chairside CAD/CAM System, available from D4D Technologies
(Richardson, Tex.).
Providing the first digital surface representation can also include
some of the above-described steps that include consolidating
various data files or images and/or designing the outer contours,
i.e., the "digital surface representation" representative of the
"outer shape" of the desired dental appliance. Such designing of
the final desired outer shape can be performed by, or can be
completed using input from, the dentist (or dental practitioner),
for example, and can include at least some of the above-described
processing, post-processing, and/or data enhancement steps. That
is, such finalizing can include manipulating the digital surface
representation using software tools to alter the shape, size,
positioning, and/or relationship to adjacent and antagonist teeth,
of all or a part of the dental appliance. Such manipulation can be
performed by a dental practitioner (e.g., a dentist, a dental
assistant, a dental lab technician, or other suitable dental
practitioner). Alternatively, the digital surface representation
formed by combining digital data files can be used without
modification (which can be referred to as a "clone" in some
software programs). In some embodiments, such finalizing or
manipulation of the digital surface representation that is
representative of the desired outer shape of the desired dental
appliance can be considered to be a part of step (ii), "forming a
first article having the desired outer shape."
The first digital surface representation can include information
relating to the outer surface or outermost shape, as well as
information regarding the inner cavity shape of the outer layer,
such as thickness of the outer shape, any internal mammelon
structure, or any other information relating to desired inner
surfaces of the outer layer (or, said another way, the desired
outer surfaces of the inner layer of the desired dental appliance).
Generally, information relating to internal mammelon structure
and/or optical properties can be input into the model manually when
designing the desired outer layer, for example, by comparing color
chips, using a color camera, choosing colors from libraries or
databases, etc.
As a result, the step of providing a first digital surface
representation can also include providing the above information
regarding the desired outer layer (or, equivalently, the desired
inner layer) as digital data files, and merging such digital data
files with any data files regarding the desired outer shape to form
the first digital surface representation. Such additional
information relating to the color, shading, and/or translucency, as
well as the depth of any such parameters, can be provided by one or
more libraries, or a patient's file history.
Such specific design characteristics may be unique for each tooth.
For example, a front incisor may be different from a rear molar.
For a two-layer dental appliance, this design information can
determine the thickness of the outer layer at each point on the
dental appliance. For example, the outer layer of the dental
appliance may be thicker near the occlusal surface than it is near
the gingival margin.
Alternatively, the outer layer may simply be set (and the first
digital surface representation adjusted accordingly) to a uniform
thickness, such as 1 mm or 2 mm. Software, particularly CAD/CAM
software associated with a fabrication tool, can allow a dental
practitioner to select between uniform thickness of the outer
layer, thickness information from a library or database, to use
software tools to customize and design the thickness of the outer
layer at various points on the dental appliance, or a combination
thereof.
Step (ii): Forming a First Article of a First Material Having the
Desired Outer Shape
Step (ii) above, "forming a first article of a first material
having the desired outer shape that corresponds to the first
digital surface representation" can include transmitting the first
digital surface representation to an appropriate fabrication tool,
and using computer-aided manufacturing (CAM) software to translate
the first digital surface representation into tooling motions,
speeds, tool types (e.g., burr sizes and shapes for subtractive
methods), and the like, to form the desired outer shape of the
desired dental appliance, based on the first digital surface
representation. The resulting preparation that includes only a
portion (e.g., the desired outer shape) of the desired dental
appliance can be referred to as a first "article," "preparation,"
or "intermediate."
The desired outer shape can be obtained using additive methods
(e.g., building up material, such as by three-dimensional ("3D")
printing, rapid-prototyping, selective laser sintering,
stereolithography, other suitable additive methods, or a
combination thereof); subtractive methods (e.g., machining from a
mill block); or a combination thereof. For example, a mill block
can be milled using a LAVA.TM. computer-integrated manufacturing
system from 3M ESPE AG (Seefeld, Germany). In some embodiments,
full chairside systems can be employed that include a scanner,
software, and one or more mills, such as the Cerec System available
from Sirona (Germany) and the E4D System available from D4D
(Richardson, Tex.).
In embodiments in which the first article having the desired outer
shape is prepared according to a subtractive process, such as
milling, the first article can remain attached to a mandrel or
frame (e.g., by a sprue) to facilitate indexing and registering the
first article in the fabrication tool for later removing a portion
(i.e., an inner portion) of the first article and forming the
desired inner shape. In some embodiments (e.g., a "chairside"
process, or a "single-appointment" or "same day" process), the
entire outer layer can be formed in the same tool (e.g., mill), and
the first article can simply remain mounted in the fabrication tool
after step (ii), and the cavity can then be formed in the first
article (i.e., in step (iii)). In some embodiments, the first
article can be considered to include the sprue, or to be coupled to
the sprue. In some embodiments, at the completion of step (ii), the
inner structures, thickness, and the like, of the outer layer may
not yet be known, and the first article can remain relatively
"block-like" and oversized.
In some embodiments, the first article can be polished, for
example, using a hand tool.
For layered, multi-chromatic dental appliances, such as dental
restorations, the first material (e.g., the mill block used in
subtractive methods) can be translucent, for example, to simulate
an enamel layer.
In some embodiments, the first material can be formed of a
polymeric material, a composite polymeric material, a
glass-ceramic, or a combination thereof. For example, when
subtractive methods are employed, the mill block from which the
desired outer shape is milled can be formed of a polymeric
material, a composite polymeric material, a glass-ceramic material,
or a combination thereof. Such composites and glass-ceramics can
both be milled in a timeframe that would allow the method to be
performed "chairside," or in a "single-appointment" or "same day"
process.
Polymeric materials (e.g., thermoplastics, such as polymethyl
methacrylate, polycarbonate, etc., or combinations thereof or
thermosets, such as epoxies, polyurethanes, etc., or combinations
thereof), or composite polymeric materials (i.e., filled polymeric
materials, sometimes referred to herein as simply "polymeric
composites" or "composites") can be used to form the dental
appliance. Because of the material properties of polymeric
materials, such materials can be used when all of the steps
(i)-(viii) will be performed chairside. In such cases, a polymeric
mill blank (e.g., a composite polymeric mill blank) can be
provided, which can be attached to a mandrel, and which can be
machined by any suitable machining equipment. Composites can
include polymeric material filled with fillers, such as inorganic
fillers (e.g., silica, zirconia, cluster fillers, other suitable
inorganic fillers, or combinations thereof).
Examples of suitable polymeric or composite polymeric materials
(i.e., filled polymeric materials) that can be employed include,
but are not limited to, Paradigm MZ100 (3M ESPE), Vita CAD Temp
Block (Vita Zahnfabrik, Germany), Telio CAD Block (Ivoclar,
Liechtenstein), other suitable composite materials, or combinations
thereof.
Glass-ceramic materials can generally be harder than polymeric
materials, and at least partly because of the material properties
of glass-ceramics, machining of the glass-ceramic may be more
time-consuming. Still, it is conceivable that all of steps
(i)-(viii) can be performed chairside when glass-ceramics are
employed.
Examples of suitable glass-ceramic materials that can be employed
include, but are not limited to, Vita Mark II (available from Vita
Zahnfabrik, Germany), Empress CAD (available from Ivoclar Vivadent,
Lichtenstein), Paradigm C (available from 3M ESPE, Seefeld,
Germany), E-Max CAD (Ivoclar Vivadent), other suitable
glass-ceramic materials, or combinations thereof.
Step (iii): Removing an Inner Portion of the First Article to Form
an Outer Layer of the Dental Appliance
Step (iii), "removing an inner portion of the first article to form
an outer layer of the dental appliance comprising a cavity
dimensioned to accommodate an inner layer," can also sometimes be
referred to as milling an internal cutback of the first article.
This step in the workflow can generally include transmitting
information regarding the desired contours and outer layer
thickness (which can be uniform or can vary at different locations
on the appliance, as described above) to a fabrication tool via CAM
software that can translate the data into tooling motions, speeds,
tool types, etc. As mentioned above, such information can form a
portion of, or be included in, the first digital surface
representation. In some embodiments, however, such information can
be provided to the fabrication tool separately from the first
digital surface representation. For example, in some embodiments,
the additional information can be a "second digital surface
representation" that needs to be merged and reconciled with the
first digital surface representation to form a first
three-dimensional digital representation comprising all of the
information regarding the outer layer. In such embodiments, the
second digital surface representation described above as being
acquired in step (vi) can be referred to as a "third digital
surface representation," which can be merged (and registered) with
the first three-dimensional digital representation to form a second
three-dimensional digital representation that includes the details
of the outer layer and the inner layer, including the desired outer
shape of the dental appliance, as well as the desired inner shape
of the dental appliance.
In some embodiments, removing a portion (e.g., an inner portion) of
the first article can include removing a substantial portion of the
first article, such that the resulting product is in the form of a
relatively thin shell that can form the outermost portion of the
desired dental appliance. For example, in some embodiments,
"removing a substantial portion" of the first article can include
removing more than 40% by volume (i.e., 40 vol %) of the first
article, in some embodiments, more than 50% by volume, in some
embodiments, more than 60% by volume, and in some embodiments, more
than 75% by volume. Removing a substantial portion of the first
article can also be defined by whether a substantially different
second article was formed when a portion of the first article was
removed and the resulting cavity was filled with a second material
(the process for which is described in greater detail below). In
some embodiments, a "substantially different" second article can
generally refer to a second article that is visually
distinguishable (e.g., by the naked human eye) from the first
article (e.g., before any portion was removed).
In some embodiments, this step can be performed by (a) inserting
the first article into the same type of machine in which the first
article was prepared (i.e., accommodating the same mandrel and
having compatibility with the same data files), if the first
article was prepared by the same method and prepared at a different
location, in a different machine; (b) inserting the first article
into the same machine (e.g., if the first article was formed at the
same location--either at the dentist's office, or in another
location); or (c) forming the cavity of the desired outer layer in
the first article that is still residing in the machine in which
the outer shape was formed (e.g., if the entire process is
chairside and the first article was never removed from the machine
in which the outer shape was formed).
The fabrication tool can then subtractively form the outer layer by
forming a cavity in the first article that will eventually be
filled with a second material that has a different optical property
(e.g., shade) than the first material of which the first article is
formed. The second material can be formed of any of the polymeric
materials, composite polymeric materials, and/or glass-ceramic
materials described above.
In some embodiments, steps (ii) and (iii) above can be done
simultaneously. For example, steps (ii) and (iii) can be performed
simultaneously in embodiments in which the first digital surface
representation includes all of the information necessary to form
the complete outer layer, which can include, for example, the
desired (e.g., final) outer shape of the dental appliance, along
with the desired internal cavity shape (e.g., any internal mammelon
structure(s)), the thickness of the outer layer, etc.
Step (iv): Forming a Second Article by Filling the Cavity of the
First Article with a Second Material Adapted to Form the Inner
Layer
The outer layer formed in steps (ii) and (iii) having a desired
outer shape (i.e., surface) and a cavity having a desired inner
shape (e.g., including any desired mammelon structure, or having a
nonspecific surface such that the outer layer has a generally
uniform thickness) can then be filled with a second material in
step (iv) to form a second article. That is, the interior cavity of
the first article can be filled with a second material to form a
second article having the desired outer shape, and the desired
outer layer. The second article also includes an inner layer having
a desired outer shape, which can be the desired inner cavity shape
of the outer layer, or which can be sized to accommodate any
intermediate layers, or a cement between the two layers. The inner
layer will later be further processed to include an overall desired
inner shape of the dental appliance. At this stage, however, the
second article generally only includes the desired outer shape of
the inner layer, and does not yet include the desired inner shape
of the dental appliance.
In some embodiments, the method of the present disclosure can stop
after step (iv), such that an exemplary method of the present
disclosure can include steps (i)-(iv) only, the resulting product
being a multi-chromatic, multi-layer intermediate dental appliance
capable of being further processed, as desired, depending on
specific patient circumstances. Such a resulting intermediate can
include or be coupled to a mandrel or frame (e.g., by a sprue) to
facilitate downstream processing.
In embodiments in which the second article having the desired outer
shape is prepared according to a subtractive process, such as
milling, the second article can remain attached to a mandrel or
frame (e.g., by a sprue) to facilitate indexing and registering the
second article in the fabrication tool for later forming the
desired inner shape (e.g., for accommodating a tooth stump, an
implant, an implant abutment, healing cap, or the like, or
combinations thereof). In some embodiments (e.g., a "chairside"
process, or a "single-appointment" or "same day" process), the
second article can simply remain mounted in the fabrication tool,
and the inner shape can be formed in the same tool in which the
outer shape was formed. The second article can either be considered
to include the sprue, or to be coupled to the sprue. At this point
in time, the lower portion of the second article (e.g., subgingival
portion) may not yet be known and can remain relatively
"block-like" and oversized, to be finalized later in the process.
It should be noted that the term "lower" is relative and depends on
the orientation of the second article.
As mentioned above, the second material can be formed of any of the
polymeric materials, composite polymeric materials, and/or
glass-ceramic materials described above, and can include a
different optical property than the first material. For example, in
some embodiments, the second material can include a flowable dental
restoration polymeric material or paste, which can be cured. As a
result, in embodiments employing a polymeric material, such as a
composite, the filling step can also include a curing step.
Such a curing step can be done by photocuring (e.g., employing
electromagnetic radiation, such as UV or visible radiation),
chemical curing, and/or thermal curing. In some cases, step (iv)
includes multiple filling and curing steps, such that the second
material can be positioned in the cavity of the first article
layer-by-layer (e.g., employing thinner layers) to compensate for
composite shrinkage and to allow curing radiation to penetrate the
composite (e.g., if a photocurable formulation is employed for the
second material).
Examples of suitable composites for the second material can further
include Filtek Supreme Flowable or Filtek Ultra, both of which are
available from 3M ESPE.
In some embodiments, the second material can be formed of a
polymeric composite which has been pre-cured and milled, e.g. from
a mill blank. This material would then be inserted and cemented to
the first article. If this technique is used, the outer layer may
not include undercuts that would prevent complete insertion of the
polymeric composite inner layer.
As a result, in the methods of the present disclosure, the second
material (which forms a layer of the dental appliance and which
generally does not include any cement or adhesive used to couple
the dental appliance to a dental object and/or to couple together
layers of the dental appliance) can be positioned in the cavity of
the outer layer, and then hardened (e.g., by curing) to form the
second article, which can be further processed (e.g.,
subtractively, such as by machining) to form the desired inner
shape of the dental appliance to accommodate a dental object.
Alternatively, the second material can be hardened and shaped
(e.g., by machining, such as milling) prior to being positioned in
the cavity of the outer layer. However, a cement (or other bonding
material or layer) that is pressed into place between the second
material and the dental object, or between the first and second
materials would not generally fall within the scope of creating a
multi-chromatic dental appliance.
In some embodiments, the second material can be formed of a
glass-ceramic material. In such embodiments, the glass-ceramic
inner layer precursor can be formed according to similar methods
used to form the outer shape of the first article. The outer shape
of the inner layer can correspond directly to the desired inner
cavity shape of the outer layer, or it can be sized to accommodate
any intermediate layers, or a cement or adhesive. The inner layer
can then be positioned in the cavity of the first article and
adhered (e.g., via a cement or adhesive) or otherwise affixed in
place to form the second article.
Furthermore, in embodiments employing a pre-formed (e.g., rigid,
solid, etc.) inner layer (e.g., formed of a cured composite or a
glass-ceramic), the cavity of the outer layer may include no
undercuts that might prevent complete insertion of the inner layer.
For example, the cavity can include a substantially uniform shape,
or even a shape that tapers to a narrower shape toward the occlusal
surface to facilitate coupling a pre-formed inner layer into the
outer layer to form the second article. Alternatively, in some
embodiments, the glass-ceramic inner layer can be formed to be
slightly smaller than the cavity of the outer layer, which can
allow the glass-ceramic inner layer to be pushed into a layer of
uncured flowable polymeric material (e.g., a composite polymeric
material), followed by a curing step to cure the polymeric material
sandwiched between the outer layer and the inner layer.
As a result, methods of the present disclosure can be used to form
multi-layer, multi-chromatic dental appliances, in which the
different layers have different aesthetic appearances, such as
different shades, different levels of
transparency/translucency/opacity, etc. The different layers
forming the resulting dental appliance may have different material
properties, or they may have similar (or the same) material
properties. If the outer layer of the resulting dental appliance
(i.e., formed of the first material) can be formed of a polymeric
material or a glass-ceramic, and the inner layer (i.e., formed of
the second material) can be formed of a polymeric or a
glass-ceramic, then the following combinations are possible: (a) an
outer layer formed of a polymeric (e.g., a composite polymeric)
material, and an inner layer formed of a polymeric (e.g., a
composite polymeric) material; (b) an outer layer formed of a
polymeric (e.g., a composite polymeric) material, and an inner
layer formed of a glass-ceramic material; (c) an outer layer formed
of a glass-ceramic material, and an inner layer formed of a
polymeric (e.g., a composite polymeric) material; and (d) an outer
layer formed of a glass-ceramic material, and an inner layer formed
of a glass-ceramic material.
All of the above combinations can be performed "chairside" or "same
day." Of the above possible material combinations, combinations (a)
and (c) may provide particular advantages. For example, filling the
cavity of the outer layer with a polymeric material and then curing
may result in a more facile, less-tedious, and/or less-restricted
process.
In some embodiments, the preceding steps (i.e., at least one of
steps (i)-(iv) of the method described above) can be performed
"off-site" and prior to the patient's visit during which the
remaining steps occur. For example, in the situation where the
first digital surface representation is acquired, at least
partially, from one or more tooth libraries (or the patient's file
history), the first article can be formed in an "off-site"
manufacturing or laboratory setting, based on the first digital
surface representation. Then, when the patient comes to the
dentist's office to receive his/her dental appliance (e.g., a
crown), the remaining steps (iii)-(vii) or (iii)-(viii) can be
performed, using the first article that was previously created.
Alternatively, in some embodiments, steps (i)-(iv) can all be
performed "off-site" and prior to the patient's visit. Then, when
the patient comes to his/her appointment to receive his/her dental
appliance, the remaining steps (v)-(vii) or (v)-(viii) can be
performed, using the second article that was previously created. In
such embodiments, at least some of the steps would be considered to
be performed "chairside." However, in some embodiments, all of the
steps (i)-(viii) can be performed during one patient visit to the
dentist's office, in which case, the entire process would be
considered to be "chairside." In some embodiments, whether the
entire process is completed sequentially at one location or some of
the steps are completed at a different time (and potentially, at a
different location), can be determined at least partially by the
materials used to form the dental appliance.
Step (v): Providing a Dental Object Having an Outer Shape
Comprising the Negative of the Desired Inner Shape of the Dental
Appliance
Step (v) of the method, "providing a dental object having an outer
shape comprising the negative (e.g., volumetric inverse) of the
desired inner shape of the dental appliance," can include preparing
a tooth by removing carious parts of the tooth to be restored,
leaving behind a tooth stump to receive the dental appliance (e.g.,
a crown; in the case of bridges, more than one tooth stump and
pontic sites may receive the dental appliance); providing or
preparing an implant, e.g., by coupling an implant abutment which
will receive the dental appliance to a previously implanted dental
implant; providing a healing cap; providing other suitable dental
objects; or combinations thereof.
Step (vi): Acquiring a Second Digital Surface Representation of the
Outer Shape of the Dental Object
Step (vi) of the method, "acquiring a second digital surface
representation of the outer shape of the dental object," can
include any of the above-described optical scanning steps to
capture digital data files representative of the dental object and
create a second digital surface representation (e.g., by using
CAD/CAM software to convert the digital data files to a
three-dimensional model).
In some embodiments, step (vi) can also include inverting the
second digital surface representation from a positive-volume
digital surface representation of the dental object to a
negative-volume digital surface representation to be formed (e.g.,
subtractively) in the second article.
In some embodiments, step (vi) can further include marking the
gingival margin (e.g., using the CAD/CAM software), which can be
done manually by the dental practitioner (e.g., dentist, assistant,
dental lab technician, etc.). The CAD/CAM software tools can be
used to create a "boundary" for the finished dental appliance.
Step (vi) can also include merging the first and second digital
surface representations (e.g., using CAD/CAM software) to register,
align, orient, and/or superimpose the two three-dimensional models
relative to one another. The first and second digital surface
representations can be registered, for example, by triangulating
the positions of the dental objected (e.g., the tooth stump) within
the digital surface representation of the first article (i.e., the
dental appliance with only the desired outer shape but not yet the
desired inner shape). This can be accomplished, for example, by
aligning duplicate and unaltered points, such as digital surface
representations of adjacent teeth or structures in the patient's
mouth, from the first and second digital surface representations.
In some embodiments, the second digital surface representation can
itself include one or more indexing or reference points to assist
in orienting or registering the second digital surface
representation with the first digital surface representation when
the two digital surface representations are merged.
In addition, in some embodiments, step (vi) can further include
digitally designing the desired inner shape of the dental appliance
to match (i.e., fit within) the already formed outer shape of the
first article. Such designing can include any of the steps
described above with respect to designing, refining or finalizing
the first digital surface representation, and can further include
translating a marked margin (if applicable) to a lower "boundary"
of the finished dental appliance, and/or designing a gap or offset
between the first digital surface representation and the second
digital surface representation in the final merged
three-dimensional digital representation to accommodate a layer of
cement, for example.
The first and second digital surface representations can be stored
at the stages of the process in which they are either provided or
created, which can be at different times and at different
locations. The first and second digital surface representations can
then later be merged or meshed together to create a final
three-dimensional model of the desired dental appliance.
In some embodiments, if the first digital surface representation is
no longer available, another (e.g., a third) digital surface
representation can be acquired by digital capturing (e.g., by
optically scanning) the second article, which already includes the
desired outer shape of the desired dental appliance. The third
digital surface representation can then act as the first digital
surface representation in the description above for the merging and
registering the inner and outer digital surface representations of
the desired dental appliance.
Step (vii): Forming the Desired Inner Shape
Step (vii), "forming the desired inner shape," can include
subtractively forming the desired inner shape in the second article
from the second digital surface representation. In some
embodiments, the desired inner shape can be formed entirely in the
inner layer of the second article; although, it is possible that
the inner shape could extend at least slightly into the outer layer
as well. In some embodiments, this step can be performed by (a)
inserting the second article into the same type of machine in which
the first article and/or outer layer were prepared (i.e.,
accommodating the same mandrel and having compatibility with the
same data files), if the first article and/or outer layer was
prepared by the same method and prepared at a different location,
in a different machine; or (b) remounting the second article into
the same machine (e.g., if the first article and/or outer layer was
formed at the same location--either at the dentist's office, or in
another location) after the second material has been positioned in
the cavity of the outer layer.
The CAD/CAM software can direct the machine to subtractively form
the desired inner shape in the second article, based on the steps
performed in step (v), to form a dental appliance having a desired
inner shape and a desired outer shape. In addition, the lower
portion of the second article can simultaneously be machined to
match the margin and to achieve a dental appliance of an
appropriate size (e.g., height).
Step (viii): Place the Dental Appliance in the Patient's Mouth
Step (viii), "placing the dental appliance in the patient's mouth,"
can include cutting the dental appliance away from the sprue, any
final firing steps (e.g., for crystallization, staining, and
glazing), any final polishing steps (e.g., before or after
placement in the patient's mouth), and/or any necessary coupling
(e.g., adhesive, curing, etc.) steps for positioning the dental
appliance in the patient's mouth (e.g., coupling to a tooth stump,
implant abutment, or another suitable dental object).
The process of staining and/or glazing a dental appliance (e.g., a
dental restoration) can include treating the outside of the
appliance (e.g., a glass-ceramic restoration) to achieve a more
natural appearance. Staining and glazing materials can be applied
using a brush and then the dental appliance can be fired (e.g., at
750-1000.degree. C.). In some embodiments, this process includes at
least two steps: at least one for staining (which generally refers
to shaded material), and at least one for glazing (which generally
refers to translucent material). Staining can also be applied to
composites using a polymeric stain, such as Sinfony Magic Shades,
available from 3M ESPE.
The dental appliance can be affixed to the dental object (e.g.,
prepared tooth stump, implant abutment, etc.) with a dental cement,
as known in the art. For example, the cavity (i.e., the cavity
defined at least partially by the desired inner shape) of the
dental appliance can be partially filled with a dental cement and
then placed over the dental object, such that the base of the
dental appliance contacts the necessary structures or tissues in
the patient's mouth. Suitable dental cements are commercially
available from 3M ESPE under the trade designation "RelyX Unicem
Self Adhesive Universal Resin Cement."
In embodiments in which glass-ceramic materials are employed, the
dental appliance having the desired inner shape and desired outer
shape can be fired, which may produce a more durable, harder
appliance. Such a firing step can be done relatively quickly, e.g.,
in some embodiments, such a firing step can be performed in less
than 30 minutes.
As mentioned above, at least one of steps (i)-(iv) can be performed
prior to the patient visit, and even at a different location. In
embodiments in which the first article and/or the second article is
formed "off-site," for example, at a dental laboratory, the
machining equipment used in the dental laboratory can be compatible
with the machining equipment used at the dentist's office, for
completion of steps (v)-(vii), such that both devices use the same
mandrel and mill blank. Such a mandrel can serve as an indexing
feature to ensure that the inner shape is formed with the correct
orientation, alignment, and relative positioning with respect to
the outer shape. In such cases, the first article (and/or the
second article) can be coupled to, or include, a sprue when it is
provided to the dentist's office for the remaining steps.
Conceivably, any remaining machining or finalizing (e.g.,
polishing, etc.) steps can also be performed off-site if the second
digital surface representation is electronically transmitted to the
dental laboratory. If the dental laboratory is geographically close
to the dentist's office, this could conceivably still result in the
entire process essentially being a chairside, or
"single-appointment" or "same day" process.
As mentioned above, the dental appliance can include a variety of
dental restorations, abutments, etc. Therefore, in some
embodiments, the dental appliance can include a dental crown
designed to be fit over a tooth stump or implant abutment. However,
in some embodiments, the dental appliance can include a bridge. The
methods of the present disclosure can be especially valuable for
bridges, which may take a long time to mill, finish and polish the
extensive outer surfaces as compared to a single unit crown. For
example, a bridge can be designed and formed comprising three (or
more) units, in which the two end units are each designed to fit
over a tooth stump or implant abutment, with one or more solid
pontics in between. In such embodiments, the outer shape can
include the outer shape of the entire bridge (or the outer layer,
including the desired outer shape and the desired inner cavity
shape of the outer layer, can include the outer layer of the entire
bridge), and the workflow can include one or more second digital
surface representations, each corresponding to a dental object. By
way of further example, one dental object could be a tooth stump,
and one could be an implant abutment. The one or more inner shapes
corresponding to the one or more second digital surface
representations can be formed simultaneously or sequentially
without departing from the spirit and scope of the present
disclosure.
The method described above is broken into eight steps by way of
simplicity and clarity. However, it should be understood that this
breakdown of the methods and workflows of the present disclosure
are by way of example only, and the method can instead include more
or fewer steps than those outlined above. For example, step (vi)
("acquiring a second digital surface representation") is described
above as including, in some embodiments, the steps of merging the
first digital surface representation and the second digital surface
representation and designing a three-dimension digital
representation of the desired dental appliance. However, it should
be understood, for example, that such steps can actually be thought
of as additional steps in the methods of the present disclosure,
and need not be considered to be a part of step (vi). Furthermore,
such additional steps may actually be performed as a part of a
different step, such as step (vii) ("forming the desired inner
shape"), or may be combined in a different way. As a result, the
present disclosure is not limited to the steps described above, or
to the separation of steps described above. One exemplary method of
the present disclosure will now be described in greater detail with
respect to FIG. 1.
FIG. 1 illustrates a method 100 according to one embodiment of the
present disclosure, for forming a dental restoration. The method
100 generally includes a first sequence 102 and a second sequence
104. The first sequence 102 and the second sequence 104 can include
some temporal overlap, such that at least some of the steps in the
first sequence 102 can occur while some of the steps in the second
sequence 104 are being performed, or vice versa. In general, the
first sequence 102 includes steps that can be performed on the
patient, while the second sequence 104 generally refers to steps
that include manipulating data, designing digital surface
representations, and/or fabricating the dental restoration. Thus,
the first sequence 102 generally takes place chairside. The second
sequence 104 can also take place chairside (or in a back room or a
portion of a dentist's office, which can also generally be referred
to as "chairside" or "single-appointment" or "same day" because the
steps are being performed while the patient is still at his/her
appointment). As described above, in some embodiments, the second
sequence 104 can take place partially chairside and partially
remotely from the location of the patient. If the remote location
is geographically near the location of the patient, however, the
entire process can still occur while the patient is at his/her
appointment, even if some of the software manipulation and/or
fabrication steps are actually performed off-site, or remote from
the location of the patient.
In the first sequence 102, a first step 106 of capturing the pre-op
condition can be performed, which can include optically scanning a
patient's soft tissue and dentition via one or more intraoral
digital scans, or optically scanning a model (e.g., a standard
model or a model of the patient's intraoral cavity), using the
above-described digital workflow techniques. As shown in step 110,
the digital data acquired from the scan can then be stored. The
digital data files stored in step 110 can then be used, for
example, at step 114, to design the outside contour of the
restoration and to create a first digital surface representation
(e.g., using CAD software). The inside contour of the desired outer
layer can also be designed at step 114.
As further shown in FIG. 1, at step 116, the outside contour of the
restoration can then be milled out of a first material using any
standard dental milling fabrication tool. As discussed above, all
of the steps 110, 114 and 116 can be performed during or prior to a
tooth preparation step 120 (described below), and/or at a dental
laboratory, remote from the dentist's office. The dental
restoration formed in step 116 is generally referred to herein as a
"first article," and the first article can be polished (e.g., while
still being coupled to the mandrel). The first material can have
certain optical properties or characteristics.
With continued reference to FIG. 1, at step 117, an outer layer of
the restoration can be formed by milling a cavity in the first
article. As described above, in some embodiments, the data
regarding the specifics of the outer layer (e.g., internal mammelon
structures, if applicable, thickness, etc.) can be included in the
first digital surface representation. Because the first article is
generally still coupled to a mandrel or frame (e.g., by a sprue),
the cavity can be formed in the first article by remounting the
first article in the same tool (e.g., mill) as that in which the
outer shape was formed, or a different tool. The mandrel can
facilitate registration of the second article in a fabrication
tool, and can assist in indexing or registering the first article
with respect to the fabrication tool when the cavity of the outer
layer is formed in the first article (described below).
Alternatively, in embodiments in which the cavity will be formed in
the same tool as the outer shape was formed, the first article can
simply remain positioned in the fabrication tool (i.e., still
coupled to or including the mandrel, sprue, etc.) after the outer
shape is formed. Furthermore, in some embodiments, as described
above, the cavity (e.g., internal surface) of the outer layer can
be formed at the same time that the outer shape (e.g., external
surface) is formed. In such embodiments, steps 116 and 117 can
occur simultaneously as one step, and the resulting product can be
a first article having the desired outer shape and the cavity.
At step 118, a second article can then be formed by filling the
cavity of the first article with a second material, namely,
composite, and curing the composite. The composite is described
with respect to the method 100 by way of example only; however, it
should be understood that other materials (such as glass-ceramics)
can be used instead, and the composite is described here and shown
in FIG. 1 by way of example only. Furthermore, as described above,
step 118 can actually include multiple layering steps, applying the
second material in thin layers, and progressively curing each
layer.
The second material will form the inner layer of the final dental
restoration, and in the exemplary method 100, the second material
has at least one different optical property (e.g., the second
material can be darker than the first material) than the first
material to form a multi-chromatic, multi-layer dental restoration.
In some embodiments of the method 100, step 118 can be the final
step, and the resulting product can be an intermediate,
multi-chromatic, multi-layer dental restoration, capable of being
further processed as needed. Such a resulting intermediate can
include or be coupled to a mandrel or frame (e.g., by a sprue) to
facilitate downstream processing.
While steps 110, 114, 116, 117 and 118 are being performed, other
actions can be taking place at the location of the patient.
Alternatively, the following steps can occur after steps 110, 114,
116, 117 and 118 are complete. At step 120, a dental object can be
formed, for example, by preparing a tooth to receive the dental
restoration by removing carious dental tissue (e.g., hard tissue),
by preparing an implant abutment (e.g., by coupling the implant
abutment to an implant), according to known methods, or a
combination thereof.
At step 126, a "post-prep" digital impression of the dental object
can then be obtained, for example, by optically scanning the dental
object.
Similar to step 114 above, the digital data files acquired at step
126 can be stored at step 130. Then, at step 134, the inside
contours of the dental restoration can be designed, and the second
digital surface representation can be formed. Also, at step 134,
the first digital surface representation and the second digital
surface representation can be merged and registered to form a
complete three-dimensional digital representation of the desired
dental restoration. In some embodiments, the second article can be
considered to include, or be coupled to, a mandrel or holder that
facilitates placement of the second article into a fabrication
tool, such as a mill. The second article can further include, or be
coupled to, a sprue that allows the second article to remain
coupled to the mandrel, but from which the final dental restoration
will be removed. The mandrel can facilitate registration of the
second article in a fabrication tool, and can assist in indexing or
registering the second article with respect to the fabrication tool
when the inner shape of the dental restoration is formed in the
second article (described below). In addition, in some embodiments,
at step 134, any manipulation of the three-dimensional digital
representation of the desired dental restoration can be performed,
and margins can be designed into the model, along with any other
necessary finalizing or data enhancement steps.
At step 136, the second article from step 118 can be milled to
achieve the desired inside contour of the dental restoration to
form the dental restoration having the desired outer shape (e.g.,
including margin(s)) and the desired inner shape.
Step 116, or the combination of steps 116, 117 and 118, can
generally be referred to as the first fabrication step, or the
"outer fabrication step," and step 136 can generally be referred to
as the second fabrication step, or the "inner fabrication step,"
even though the inner fabrication step can include any finalizing
that needs to be done with respect to the outer shape of the dental
restoration. As a result, the fabrication steps for forming the
inner shape of the dental restoration can be separated from and
performed subsequently to steps for fabricating the outer shape of
the dental restoration (with the exception of margins, or any
additional finalizing of the outer shape, which can also be
performed at step 136). As mentioned above, steps 116-118 need not
be entirely completed before step 120 begins. Rather, steps 120 and
126 can occur while any of steps 110, 114, 116, 117 and 118 are
still being performed.
Finally, as shown in FIG. 1, the method can include step 140, in
which the completed restoration is placed in the patient's mouth,
for example, using any cementation techniques known in the art.
In some embodiments, the method 100 can be described as including a
first (or "outer") sequence 142 for creating the outer shape of the
desired dental restoration, and a second (or "inner") sequence 144
for creating the inner shape of the desired dental restoration. In
some embodiments, the outer sequence 142 can include steps 106,
110, 114, 116, 117 and 118, and the inner sequence 144 can include
steps 120, 126, 130, 134 and 136. At least a portion of the outer
sequence 142 can overlap temporally with the inner sequence 144,
such that the inner sequence 144 can be initiated before the outer
sequence 142 has been fully completed. Furthermore, as described
above, the outer sequence 142 can be performed prior to the
patient's visit, such that the second article is already prepared
and ready for the inner sequence 144 to be completed when the
patient arrives for his/her appointment. Alternatively, as
described above, both the outer sequence 142 and the inner sequence
144 can be completed while the patient is at his/her appointment.
In either scenario, the patient can leave the appointment with the
desired dental restoration in place in his/her mouth.
Furthermore, in some embodiments, the outer sequence 142 can
generally include a first sequence 146 for forming the first
article, and a second sequence 148 for forming the second article.
In the first sequence 146, the desired outer shape can be milled
into a mill block of a desired first material having a desired
optical property (e.g., shade) to form the first article (i.e.,
step 116 in FIG. 1), and then a cavity can be milled out of the
first article to form an outer layer of the dental restoration that
includes the desired thickness, internal mammelon structure(s),
translucency, etc. (i.e., step 117 in FIG. 1). In some embodiments,
forming the cavity in the first article (i.e., step 117 in FIG. 1)
can be considered to be a part of the first sequence 146, and in
some embodiments, forming the cavity can be considered to be a part
of the second sequence 146. The second sequence 148 can include
forming the second article by filling the cavity in the first
article with a second material having a different optical property
(e.g., shade) than the first material, such that the second article
is multi-chromatic, and includes at least two layers.
As mentioned above, steps 117 and 118 can be repeated as many times
as desired to form a second article having the desired number of
layers, the desired level of multi-chromaticity, the desired outer
shape of the dental restoration, and the inner layer, in which the
desired final inner shape of the dental restoration will be formed
(i.e., step 136).
The method 100 is shown in FIG. 1 and described above for
illustration purposes only, and it should be understood that the
methods of the present disclosure are not limited to the specific
embodiment shown in FIG. 1 and described above.
The following is a description of various embodiments of the
present disclosure.
EMBODIMENTS
Embodiment 1 is a method of making a dental appliance, the method
comprising: providing a first digital surface representation of a
desired outer shape of a dental appliance; forming a first article
of a first material having the desired outer shape based on the
first digital surface representation; removing an inner portion of
the first article to form an outer layer of the dental appliance
comprising a cavity dimensioned to accommodate an inner layer; and
forming a second article by filling the cavity of the first article
with a second material adapted to form the inner layer, wherein the
second material has at least one optical property that is different
from the first material.
Embodiment 2 is a method of making a dental appliance, the method
comprising: providing a first digital surface representation of a
desired outer shape of a dental appliance; forming a first article
of a first material having the desired outer shape based on the
first digital surface representation; removing an inner portion of
the first article to form an outer layer of the dental appliance
comprising a cavity dimensioned to accommodate an inner layer;
forming a second article by filling the cavity of the first article
with a second material adapted to form the inner layer, wherein the
second material has at least one optical property that is different
from the first material; providing a dental object having an outer
shape comprising the negative of a desired inner shape of the
dental appliance; acquiring a second digital surface representation
of the outer shape of the dental object; and subtractively forming
the desired inner shape in the second article based on the second
digital surface representation to form the dental appliance having
the desired inner shape and the desired outer shape; wherein at
least one of providing a dental object and acquiring a second
digital surface representation occurs during or after at least one
of forming a first article, removing an inner portion of the first
article, and forming a second article, and wherein subtractively
forming the desired inner shape occurs separately from and
subsequently to forming a first article of a first material having
the desired outer shape.
Embodiment 3 is the method of embodiment 1 or 2, further comprising
repeating the removing an inner portion of the first article step
and the forming a second article step as many times as desired to
form a second article having a desired number of layers and
comprising the inner layer.
Embodiment 4 is the method of any of embodiments 1-3, wherein the
second material is different from the first material.
Embodiment 5 is the method of any of embodiments 1-4, wherein the
first material has a different shade than the second material.
Embodiment 6 is the method of any of embodiments 1-5, wherein the
first material is shaded to mimic an enamel layer, and wherein the
second material is shaded to mimic a dentin layer.
Embodiment 7 is the method of any of embodiments 1-6, wherein the
first material is formed of at least one of at least one of a
polymeric composite and a glass-ceramic.
Embodiment 8 is the method of any of embodiments 1-7, wherein the
second material is formed of at least one of at least one of a
polymeric composite and a glass-ceramic, and wherein the second
material includes at least one optical property that differs from
the first material.
Embodiment 9 is the method of any of embodiments 1-8, wherein the
first material is formed of a glass-ceramic or a polymeric
composite material, and wherein the second material is formed of a
polymeric composite material.
Embodiment 10 is the method of any of embodiments 1-9, wherein the
dental object includes at least one of a tooth stump, an implant,
an implant abutment, a healing cap, and a combination thereof.
Embodiment 11 is the method of any of embodiments 1-10, wherein
forming a first article of a first material having the desired
outer shape includes forming a first article by an additive
process.
Embodiment 12 is the method of any of embodiments 1-10, wherein
forming a first article of a first material having the desired
outer shape includes forming a first article by a subtractive
process.
Embodiment 13 is the method of any of embodiments 1-10 and 12,
wherein forming a first article of a first material having the
desired outer shape includes machining the desired outer shape from
a mill block.
Embodiment 14 is the method of embodiment 13, wherein the mill
block is formed of a polymeric composite material.
Embodiment 15 is the method of any of embodiments 1-14, wherein
subtractively forming the desired inner shape in the second article
includes machining the desired inner shape.
Embodiment 16 is the method of any of embodiments 1-15, wherein
subtractively forming the desired inner shape in the second article
includes milling the desired inner shape.
Embodiment 17 is the method of any of embodiments 1-16, wherein
acquiring a second digital surface representation of the outer
shape of the dental object includes optically scanning the dental
object.
Embodiment 18 is the method of any of embodiments 1-17, wherein at
least two of forming a first article, removing an inner portion of
the first article, and subtractively forming the desired inner
shape in the second article are performed by the same fabrication
tool.
Embodiment 19 is the method of any of embodiments 1-18, wherein at
least two of forming a first article, removing an inner portion of
the first article, and subtractively forming the desired inner
shape in the second article occur at different locations from one
another.
Embodiment 20 is the method of any of embodiments 1-19, further
comprising acquiring a third digital surface representation of the
second article.
Embodiment 21 is the method of any of embodiments 1-20, further
comprising merging the first digital surface representation and the
second digital surface representation to form a three-dimensional
digital representation of the dental appliance.
Embodiment 22 is the method of any of embodiments 1-21, further
comprising designing a three-dimensional digital representation of
the dental appliance, wherein designing a three-dimensional digital
representation includes merging the first digital surface
representation and the second digital surface representation.
Embodiment 23 is the method of embodiment 22, wherein designing a
three-dimensional digital representation of the dental appliance
further includes orienting the first digital surface representation
and the second digital surface representation with respect to one
another.
Embodiment 24 is the method of embodiment 22, wherein designing a
three-dimensional digital representation of the dental appliance
further includes designing an offset between the first digital
surface representation and the second digital surface
representation to accommodate a cement or adhesive.
Embodiment 25 is a method of making a dental appliance, the method
comprising: providing a first digital surface representation of a
desired outer shape of a dental appliance; forming a first article
of a first polymeric material having the desired outer shape based
on the first digital surface representation; removing an inner
portion of the first article to form an outer layer of the dental
appliance comprising a cavity dimensioned to accommodate an inner
layer; forming a second article by filling the cavity of the first
article with a second polymeric material, wherein the second
polymeric material has at least one optical property that is
different from the first polymeric material; curing the second
polymeric material to form the inner layer; providing a dental
object having an outer shape comprising the negative of a desired
inner shape of the dental appliance; acquiring a second digital
surface representation of the outer shape of the dental object; and
subtractively forming the desired inner shape in the second article
based on the second digital surface representation to form the
dental appliance having the desired inner shape and the desired
outer shape; wherein at least one of providing a dental object and
acquiring a second digital surface representation occurs during or
after at least one of forming a first article, removing an inner
portion of the first article, and forming a second article, and
wherein subtractively forming the desired inner shape occurs
separately from and subsequently to forming a first article having
the desired outer shape.
Embodiment 26 is the method of embodiment 25, further comprising
repeating the removing an inner portion of the first article step
and the forming a second article step as many times as desired to
form a second article having a desired number of layers and
comprising the inner layer.
Embodiment 27 is the method of embodiment 25 or 26, wherein forming
a second article by filling the cavity with a second polymeric
material and curing the second polymeric material can be repeated
as many times as desired.
Embodiment 28 is the method of any of embodiments 25-27, wherein at
least one of the first polymeric material and the second polymeric
material is a composite polymeric material.
The following working example and prophetic example are intended to
be illustrative of the present disclosure and not limiting.
EXAMPLES
Preparatory Example 1
Preparation of a Dental Blank Assembly Used in Example 1
Support (Mandrel) Fabrication
A commercially available metal mandrel designed to fit into a Cerec
3 milling unit (Sirona, Germany) was scanned with a LAVA.TM. ST
Scanner (3M ESPE). The scan data were used to mill a LAVA.TM.
Zirconia mill blank (3M ESPE) into the same shape as the metal
mandrel, factoring in a shrinkage parameter such that the zirconia
mandrel was the proper size after sintering. The milled zirconia
was fully sintered per manufacturer's instructions in a LAVA.TM.
Furnace 200 (3M ESPE), thus producing a fully sintered zirconia
mandrel.
Mill Blank Attachment to the Mandrel
A feldspathic porcelain (Vita Mark II, Shade A3, Vident, Bad
Sackingen, Germany) mill blank not having a mandrel was placed on a
surface and a slurry of Vita VM9 porcelain (Vident) and LAVA.TM.
Ceram Modeling Liquid (3M ESPE) was liberally painted on both the
mill blank and the sintered zirconia mandrel. The mandrel was then
pressed onto the blank using finger pressure and the assembly was
carefully placed into a furnace (Vita Vacumat 4000T, Vident) and
fired using the following temperature profile: 500 deg. C. for 6
min., then ramped at 25 deg. C./minute to 910 deg. C. and held at
910 deg. C. for 3 minutes. The vacuum was on during the heating and
released when the temperature reached 910 deg. C. The fired
assembly was slow cooled to 600 deg. C. and then cooled to room
temperature, thus producing a mill blank attached to a mandrel
(dental blank assembly).
Example 1
Chairside Preparation of an all-Ceramic Multi-Chromatic Dental
Restoration for a Patient Needing a Full Crown
Using a Cerec 3 milling unit, an external shape in the form of an
anterior prep was selected from the software library. Using the
same software, an internal cavity was designed to have the same
shape as the external surface, but being about 1 mm smaller, thus
leaving a 1 mm exterior shell. This design of the outer layer of
the restoration was then sent to the milling unit and milled from
the dental blank assembly of Preparatory Example 1 to form the
outer layer (which includes the desired outer shape and an internal
cavity) of the restoration. A sprue was left, attaching the outer
layer to the mandrel (thereby forming a "second assembly"). The
outer layer and mandrel (i.e., the "second assembly") were removed
from the mill.
The hollow interior of the outer layer was then positioned with the
open base facing upwards and filled with a slurry of Vita VM9
(enamel shade, Vident) and LAVA.TM. Ceram Modeling Liquid. The
filled outer layer (i.e., the second article), still attached to
the mandrel (i.e., the third assembly comprising the second article
coupled to the support), was carefully placed into a Vita Vacuumat
4000T furnace and subsequently fired using the following
temperature profile: 500.degree. C. for 6 min., ramped at
25.degree. C./minute to 910.degree. C. and held at 910.degree. C.
for 3 min. The vacuum was on during the heating and released when
the temperature reached 910.degree. C. The fired assembly was slow
cooled to 600.degree. C., and then cooled to room temperature, thus
producing a two-layer restoration having different shades for the
interior and exterior and having an unfinished shape at the base
still attached to the mandrel via the sprue.
Further Prophetic Steps
While the milling procedure is occurring, the dentist prepares the
patient's tooth, removing carious material and leaving a stump to
which the restoration will be attached. A scan is taken of the
preparation, digitized, the practitioner marks the margin, and the
3D model of the preparation is meshed with the 3D model of the
restoration to determine a new internal surface for milling which
is based on the preparation, margin and external shape of the
restoration. The internal milling pathway is recalculated to sync
with the previous milling pathway but the outer geometry is left as
previously milled. In the new CAM milling pathway, the block
geometry is calculated based on the shape generated in the previous
steps (i.e., the desired inner shape is milled from the two-layer
restoration attached to the mandrel).
The unfinished restoration is re-inserted into the mill, the
margins and cavity for the preparation are milled, and the finished
restoration is removed from the sprue and polished, thus forming a
completed restoration ready for cementation to the preparation.
Example 2
Prophetic Example of a Chairside Preparation of a Multi-Chromatic
Dental Restoration for a Patient Needing a Full Crown
A preoperative scan is taken of the tooth requiring restoration as
well as the data from the adjacent and antagonist dentition using
an intraoral scanning system such as the Lava Chairside Oral
Scanner (C.O.S.; available from 3M ESPE). This data is then
digitized and used to create a digital 3D model (i.e., a first
digital surface representation) of the patient's teeth. The 3D
model is then used to design the external surface (i.e., the
desired outer shape) of the restoration. The shape and size of the
existing tooth is desired for replication, so the external surface
is cloned (i.e. not modified) using E4D design software (D4D
Technologies, Richardson, Tex.). At this time, the gingival portion
and margin of the restoration are left unfinished.
Using the same software, an internal cavity is designed to have the
same shape as the external surface, but being 1 mm smaller, thus
leaving a 1 mm exterior shell. The design of an outer layer of the
restoration is now sent to a milling system (D4D) and milled from
an MZ100 enamel shaded block of composite (3M ESPE) to form a first
article comprising the outer layer (which includes the desired
outer shape and an internal cavity). A sprue is left, attaching the
first article to the mandrel. The semi-finished restoration (i.e.,
the first article) is removed from the mill.
The hollow interior of the outer layer is first treated with an
adhesive such as Adper Easy Bond Self Etch Adhesive (3M ESPE), then
filled with dentin-shaded Filtek Supreme Plus Universal composite
(3M ESPE) and photocured using an Elipar S10 curing lamp (3M ESPE)
to form a second article comprising two layers of different shades.
The filled restoration (i.e., the second article) is now reinserted
into the mill for the final milling step.
While the milling procedure is occurring, the dentist prepares the
patient's tooth, removing carious material and leaving a stump to
which the restoration will be attached.
A scan is taken of the preparation, digitized, the practitioner
marks the margin, and the 3D model of the preparation is meshed
with the 3D model of the restoration to determine a new internal
surface for milling which is based on the preparation, margin and
external shape of the restoration. The internal milling pathway is
recalculated to sync with the previous milling pathway but the
outer geometry is left as previously milled. In the new CAM milling
pathway, the block geometry will be calculated based on the shape
generated in the previous steps (i.e., the desired inner shape is
milled from the second article).
The margins and cavity for the preparation are milled and the
finished restoration is removed from the sprue and polished, thus
forming a completed restoration ready for cementation to the
preparation.
The embodiments described above and illustrated in the figures are
presented by way of example only and are not intended as a
limitation upon the concepts and principles of the present
disclosure. As such, it will be appreciated by one having ordinary
skill in the art that various changes in the workflow steps and
their configuration are possible without departing from the spirit
and scope of the present disclosure. Various features and aspects
of the present disclosure are set forth in the following
claims.
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